Method of making continuous fiber glass filament open weave frames and structures

ABSTRACT

A lattice-like frame is formed by extending a resin saturated strand of filaments angularly between pins secured to opposing end surfaces of a frame-work support. The pins and frame-work support are removed after the resin has set.

March 14, 1972 D, B, GUNNERSQN 3,649,401

METHOD 0E MAKING CONTINUOUS EIEEE GLASS EILAM'ENT OPEN wEEvE FRAMES AND STRUCTURES Filed 0G11. 28. 1968 O WMM FIGB DALE B. GUN N ERSON /NVENTOR United States Patent O METHOD F MAKING CONTINUOUS FIBER GLASS FILAMENT OPEN WEAVE FRAMES AND STRUCTURES Dale B. Gunnerson, 1978 Lindsay Drive,

Salt Lake City, tali 84119 Filed Oct. 28, 1968, Ser. No. 771,230 Int. Cl. B65h 81/00 U.S. Cl. 156-175 5 Claims ABSTRACT OF THE DISCLOSURE A lattice-like frame is formed by extending a resin saturated strand of filaments angularly between pins secured to opposing end surfaces of a frame-work support. 'Ihe pins and frame-work support are removed after the resin has set.

BACKGROUND OF THE INVENTION The present invention relates to frame structures and more particularly to a method of making open weave or lattice-type pedestal-like supports for articles of furniture and the like.

Some of the furniture frame supporting structures have been recently directed toward frames formed of wire-like material or interconnected rods or tubes to impart an open frame-work appearance and achieve a light weight article. This open frame-work type structure has also been accomplished by the use of fiber strand material known as wicker furniture. The use of wire, rods, and tubing as well as the skill and tools necessary for assembly adds considerable to the cost of such furniture structure frames. Similarly the limits of the use of the fiber strand, forming Wicker material, is limited -because it requires that a rigid frame be formed for supporting the strands forming or completing the various structures.

This invention provides a means and method of forming an open woven or lattice-like appearing pedestal forn1- ed of -eXible strand material temporarily supported by a frame or frame support wherein a synthetic coating, applied to the strand, cures or hardens with age and forms a rigid self-supporting frame-work when the temporary frame support has been removed. This lattice-type frame structure can be made in a variety of substantially unlimited coniigurations as well as tightly woven as opposed to an open or loose weave. Any color desired can be achieved by coloring the impregnating resin or applying color to the lattice-like weave after the resin has set. Furthermore, this lattice-type structure may be permanently joine'd with base and top supports by casting a synthetic marble-like section, or the like, around the respective end portion of the lattice-type structure.

SUMMARY OF THE INVENTION A temporary knockdown frame, having a desired configuration to achieve a selected design for a finished article, is provided around its respective peripheral ends with removable pins or hooks. An elongated strand formed of continuous fiber glass filaments is saturated with polyester resin and is strung from one pin to another at respective end portions of the temporary frame in an alternating manner from each end of the frame and progressing from one pin to another in one direction around the frame and then overlapping in the opposite direction around the frame. The device is then left to permit the resin to harden and thereafter the pins are removed to remove the temporary frame. This forms a lattice-type structure which may then have its respective end portions permanently attached with base or top members, such as by casting the end portions in synthetic marble material, or the like.

r3Ice The principal object of this invention is to provide a means and method for making pedestal type lattice appearmg support structures.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. l is a perspective View illustrating the manner of carrying out the invention;

FIG. 2 is a side elevational view, to a larger scale, of the completed structure of FIG. 1;

FIG. 3 is an alternative configuration of the structure;

FIG. 4 is a side elevational view of the structure of FIG. 2 superposed on the structure of FIG. 3 and illustrating a fragmentary portion of a -base and top secured to lts respective ends;

FIG. 5 is an end view of FIG. 4 with the base and top removed;

FIG. 6 is a perspective view, to a smaller scale, illustrating a manner of casting a synthetic marble base around the fragmentary end portion of the structure of FIG. 4;

FIG. 7 is a perspective view, to a different scale, of an alternative manner of forming the structure for supporting a table and the like; and,

FIG. 8 is an enlarged fragmentary perspective view, partially in section, illustrating the general appearance and structure of the strand used in forming the structure.

DESCRIPTION OF THE PREFERRED 'EMBODIMENTS Like characters of reference designate like parts in those figures of the drawings in which they occur.

In the drawings:

The reference numeral 10 indicates an elongated strand formed by a plurality of continuous fiber glass filaments, indicated at 12, bonded together by a polyester resin.

In carrying out the invention the strand 10 is saturated with the resin and then woven or strung from one point to another in consecutive sequence to form a lattice-like or woven pattern structure while the resin remains in a iiuid state. After the resin has had time to set up or harden the resulting pattern or structure is substantially rigid and cannot `be altered.

One manner of forming a pedestal-like structure is illustrated in FIGS. l to 5, which comprise providing a temporary knockdown frame, such as is shown in FIG. l, including end plates or caps 14 and 16 disk-like in configuration maintained in parallel spaced relation by a mandrel or centrally connected shaft 18. The peripheral edge of the caps 14 and 16 are each provided with a series of spaced-apart hooks, nails or pins 20 in selected spaced relation, for example 10. `One end of the elongated strand 10, impregnated with resin, is secured to one of the pins 20 and is extended tautly to a selected pin or pins on the other cap and then alternately between the caps while progressing from one or more pins to another and then reversing the Stringing of the strand in the other direction around the caps until a complete lattice pattern surrounds the temporary frame. This results in a lattice-type structure having the configuration illustrated in FIG. 2. Alternatively the sequence of Stringing the strand 10 from the pins on one cap to pins on the other cap may be selected to form a lattice-work having an outer surface dening a hyperboloid of revolution, such as is illustrated in FIG. 3.

FIG. 4 illustrates the manner in which the lattice-work, illustrated by FIGS. 2 and 3, may be superposed one upon the other by first forming the design of FIG. 3 and subsequently weaving or Stringing the strand or design of FIG. 2 thereon. The work is then left at room temperature to permit the resin to set or harden. After the resin has set, the pins 20 are removed thus permitting removal of the knockdown frame comprising the caps 14, 16 and mandrel 18. 'The result is a rigid lattice-like structure 25 for a selected purpose, such as a stand as is illustrated by FIG. 4, wherein a base 22 and top 24 are rigidly connected with the respective ends of the structure 25. This is accomplished by providing a substantially horizontally disposed platform 26 having a ring 28, fence or retaining wall structure overlying the upper surface of the platform 26. One end portion of the structure 2S is centrally positioned within the ring 28 which is then iilled with synthetic material, such as plastic to form the marble in appearance base 22 which is allowed to harden around the woven strand defining one end portion of the structure the top 24 is formed in an identical manner.

As mentioned hereinabove the lattice-type structure may be selectively formed in different designs for different purposes and referring more particularly to FIG. 7, a relatively large strand is formed identical with the strand 10 and woven or strung in a criss-cross arcuate or wave-like pattern, such as is illustrated at 30. After this strand has set or hardened it forms a support for a table top 32, or the like, which is secured to the woven strands forming the support therefor, preferably by casting the top 32 around the strands.

While tiber glass filaments have been named it seems obvious that other continuous or monoiilaments, such as cotton thread or synthetic material, -presently marketed under the trade names rayon and nylon may be used. Similarly, the resin used may be any of the plastic resins having the properties of impregnating a strand of lilaments and setting up or hardening within a predetermined time and temperature range for bonding the strands into a single impervious rigid strand.

I claim:

1. The method of forming an ornamental structure, comprising: providing a knockdown frame having end plates maintained in space relation by a central mandrel and having a series of removable spaced-apart strand supporting pins projecting outwardly of the respective peripheral surface of the end plates; providing an elongated ilexible strand of juxtaposed continuous ber glass filaments; saturating said strand with polyester resin at room temperature; Stringing said strand between said pins on each end plate and between said pins on one end plate to said pins on the other end plate in a predetermined crisscrossed pattern; allowing the polyester resin to set; and removing said pins and said frame.

2. The method according to claim 1 and further including the steps of: providing a horizontal upwardly open mold; placing one end portion of said ornamental structure in said mold; lling said mold with a plastic material; allowing said plastic material to set; and removing said mold.

3. The method according to claim 1 in which the strand Stringing sequence forms an outer surface for said ornamental structure defined by a hyperboloid of revolution.

4. The method according to claim 1 in which the strand is formed of monotilament synthetic material.

5. The method according to claim 1 in which the strand is formed of monofilament synthetic material.

References Cited UNITED STATES PATENTS 3,196,061 7/1965 Paulson et al. 156-296 3,203,845 8/1965 Short 156-175 3,477,892 Ill/1968 Plymale 156-175 X CARL D, QUARFORTH, Primary Examiner S. J. LECHERT, JR., Assistant Examiner U.S. Cl. X.R. 156-180, 245, 296

P04050 UNITED STATES PATENT OEHCE 569 CERTIFICATE OF CORRECTION Patent NO- 3.649.401 hated` March 14, 1972 Inventods) Dale B. Gunnerson It is certified that error appears in the vabove-i'dentifed patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line l2, lplace a Period ff) after "ture" and capitalize "the" (The) Column 4, line 23, "monofilament synthetic" shold read fibrous.

Signed and sealed this 10th day of' October 1.972.

(SEAL) Attest:

`EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner' of Patents 

